Pocketed spring seating unit

ABSTRACT

An apparatus and method are provided for a pocketed spring seating unit to be incorporated into a couch or sofa. The pocketed spring seating unit comprises a spring array that includes a multiplicity of pocketed springs disposed in a spring layer arrangement. Each of the pocketed springs comprises an independently operable coil spring covered with a flexible wrap. An envelope comprising insulating materials surrounds the spring array. The spring array and the envelope are attached to a rigid platform that is disposed below the envelope. The rigid platform has a length and width that match a seating area of the couch or sofa and is configured such that the pocketed spring seating unit may be laid into an upholstery frame of the couch or sofa. An exterior cloth material overlays one or more exterior surfaces of the pocketed spring seating unit.

PRIORITY

This application claims the benefit of and priority to U.S. Provisional Application, entitled “Pocketed Spring Seating Unit,” filed on Apr. 11, 2016 and having application Ser. No. 62/321,084.

FIELD

The field of the present disclosure generally relates to furniture. More particularly, the field of the invention relates to an apparatus and a method for a durable spring seating unit which conforms to the shape of a person's body, conveys superior comfort, will not bottom-out, and maintains an original performance more effectively than conventional spring seating units.

BACKGROUND

A couch or sofa is a piece of furniture in the form of a bench, with or without armrests, suitable for seating two or more people. A sofa typically is upholstered and fitted with tailored seat cushions that are positioned atop of a spring seating unit configured to comfortably support a seated person.

A drawback to conventional spring seating units, however, is a limited capacity for conforming to the seated person's body, and thus limited comfort is conveyed to the seated person. Conventional spring seating units generally comprise eight-way-hand-tied seating units, drop-in seating units, and no-sag seating units. As shown in FIG. 1, an eight-way-hand-tied seating unit 80 typically comprises an array of coil springs 82 sitting on a fabric decking material and each coil spring is held in place by eight points of tied, non-stretch twine. Although this system provides a deep seating experience afforded by the coil springs, the twine that connects the springs together and connects the springs to the frame restricts the otherwise free, independent movement of the springs, resulting in a limited ability to track shapes on the seating surface. Another drawback is that hand-tying is an extremely time-consuming and difficult method of construction, and thus eight-way-hand tied seating units are more expensive than most of the marketplace may be able to afford.

FIG. 2 illustrates a conventional drop-in seating unit 84 that comprises a pre-fabricated array of coil springs 88 that are tied in place with wire. The drop-in seating unit 84 typically is set into an upholstery frame and attached thereto with fasteners. Although less expensive, drop-in seating units provide a similar but slightly inferior seating experience than an eight-way-hand-tied seating unit. The free movement of the coil springs 88 is even more limited by the more restrictive steel wire connections. Further, the metal wire attachments cause horizontal loads on the upholstery frame, and thus the upholstery frame requires structural strengthening to compensate. Although drop-in seating units are somewhat less expensive than eight-way-hand-tied seating units, drop-in seating units do not perform as well and thus are infrequently used.

FIG. 3 illustrates a conventional no-sag seating unit 92 incorporated into an exemplary sofa back 96. As will be recognized, no-sag seating units currently are the standard within the furniture industry. As shown in FIG. 3, the no-sag seating unit 92 comprises a series of flat, sinuous springs 100 that are supported by metal clip attachments on the front and the rear of the frame. Approximately 90% of seating units utilize no-sag spring technology due to the affordability to a majority of the marketplace. Although no-sag seating units are the most economical, there are many drawbacks, including a relatively shallow seating depth due to the flat springs, an inability to contour to body shapes, as well as each flat spring exerting an approximately 80-pound horizontal force on the wood frame when deflected. As will be recognized, the connections between the flat springs and the wood frame are a common failure point.

What is needed, therefore, is a spring seating unit which is durable, exerts relatively little stress on the frame, offers superior conformity to a wide variety of different body shapes, delivers a more luxurious seating experience, and is generally affordable in the marketplace.

SUMMARY

An apparatus and method are provided for a pocketed spring seating unit to be incorporated into a couch or sofa. The pocketed spring seating unit comprises a spring array that includes a multiplicity of pocketed springs disposed in a spring layer arrangement. Each of the pocketed springs comprises an independently operable coil spring covered with a flexible wrap. An envelope comprising insulating materials surrounds the spring array. The envelope may be comprised of a combination of polyurethane and polyester padding. The spring array and the envelope are attached to a rigid platform that is disposed below the envelope. The rigid platform has a length and width that match a seating area of the couch or sofa and is configured such that the pocketed spring seating unit may be laid into an upholstery frame of the couch or sofa. The rigid platform is configured to support the spring array such that at least a portion of the multiplicity of pocketed springs compress optimally under the weight of a seated person without placing undue stress on the upholstery frame. An exterior cloth material overlays one or more exterior surfaces of the pocketed spring seating unit.

In an exemplary embodiment, a pocketed spring seating unit for a couch or sofa comprises a spring array comprised of a multiplicity of pocketed springs disposed in a spring layer arrangement; an envelope comprised of insulating materials and surrounding the spring array; a rigid platform disposed below the envelope, the spring array and the envelope being attached to the rigid platform; and an exterior cloth material overlaying at least a portion of the envelope and the rigid platform.

In another exemplary embodiment, each of the multiplicity of pocketed springs comprises a coil spring covered with a flexible wrap. In another exemplary embodiment, the coil spring is comprised of metal and configured to be compressed to a spring travel depth of at least 70% of the height of the coil spring when uncompressed. In another exemplary embodiment, each of the multiplicity of pocketed springs is configured to operate independently.

In another exemplary embodiment, the envelope is comprised of at least a bottom insulating pad. In another exemplary embodiment, the envelope is comprised of at least a bottom insulating pad, a top insulating layer, and a side insulating layer. In another exemplary embodiment, at least the bottom insulating pad and the top insulating layer are comprised of a combination of polyurethane and polyester padding. In another exemplary embodiment, the side insulating layer extends along the perimeter of the spring array and is disposed between the bottom insulating pad and the top insulating layer. In another exemplary embodiment, the side insulating layer is comprised of one or more pieces of insulating material disposed around the perimeter of the spring array.

In another exemplary embodiment, the rigid platform has a length and a width that suitably match a seating area of the couch or sofa. In another exemplary embodiment, the rigid platform is comprised of plywood, or a similar material. In another exemplary embodiment, the rigid platform is configured such that the pocketed spring seating unit may be laid into an upholstery frame of the couch or sofa. In another exemplary embodiment, the rigid platform is configured to support the spring array such that at least a portion of the multiplicity of pocketed springs compress optimally under the weight of a seated person without placing undue stress on an upholstery frame of the couch or sofa. In another exemplary embodiment, the multiplicity of pocketed springs are configured to exhibit substantially vertical forces borne by the rigid platform, such that an absence of a substantial horizontal force is exerted on the upholstery frame. In another exemplary embodiment, the pocketed spring seating unit is configured to be lifted vertically from an upholstery frame of the couch or sofa during servicing of the upholstery frame.

In an exemplary embodiment, a method for a pocketed spring seating unit to be incorporated into a couch or sofa comprises arranging a multiplicity of pocketed springs into a spring array; enclosing the spring array within an envelope of insulating materials; attaching the envelope and the spring array to a rigid platform; and overlaying an exterior cloth material onto one or more exterior surfaces of the envelope and the rigid platform.

In another exemplary embodiment, arranging further comprises orienting the multiplicity of pocketed springs side by side so as to form a spring layer. In another exemplary embodiment, enclosing further comprises forming the insulating materials of a combination of polyurethane and polyester padding. In another exemplary embodiment, attaching comprises fastening the envelope and the spring array to the rigid platform by way of glue and suitable fasteners. In another exemplary embodiment, attaching further comprises configuring the rigid platform with a length and a width that suitably match a seating area of the couch or sofa.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings refer to embodiments of the present disclosure in which:

FIG. 1 illustrates a conventional eight-way-hand-tied seating unit comprising an array of coil springs sitting on a fabric decking material and held in place by eight points of tied twine;

FIG. 2 illustrates a conventional drop-in seating unit that comprises a pre-fabricated array of coil springs that are tied together with metal wire attachments;

FIG. 3 illustrates a conventional no-sag seating unit that is incorporated into an exemplary sofa back; and

FIG. 4 illustrates a cross-sectional view of an exemplary embodiment of a pocketed spring seating unit according to the present disclosure.

While the present disclosure is subject to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. The invention should be understood to not be limited to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one of ordinary skill in the art that the invention disclosed herein may be practiced without these specific details. In other instances, specific numeric references such as “first spring,” may be made. However, the specific numeric reference should not be interpreted as a literal sequential order but rather interpreted that the “first spring” is different than a “second spring.” Thus, the specific details set forth are merely exemplary. The specific details may be varied from and still be contemplated to be within the spirit and scope of the present disclosure. The term “coupled” is defined as meaning connected either directly to the component or indirectly to the component through another component. Further, as used herein, the terms “about,” “approximately,” or “substantially” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of components to function for its intended purpose as described herein.

In general, the present disclosure describes an apparatus and a method for a pocketed spring seating unit to be incorporated into a couch or sofa. The pocketed spring seating unit comprises a spring array that includes a multiplicity of “pocketed” springs disposed in a spring layer arrangement. Each of the pocketed springs comprises a coil spring enclosed within a flexible wrap and operates independently. Preferably, the coil springs are comprised of spring steel and configured to have a spring travel depth when compressed ranging between substantially 0 inches and approximately 70% of the spring height. An envelope comprising insulating materials surrounds the spring array. In some embodiments, the envelope may be comprised of a combination of polyurethane and polyester padding. The spring array and the envelope are attached to a rigid platform disposed below the envelope. The rigid platform has a length and width that match a seating area of the couch or sofa and is configured such that the pocketed spring seating unit may be laid into an upholstery frame of the couch or sofa. An exterior cloth material overlays one or more exterior surfaces of the pocketed spring seating unit.

FIG. 4 illustrates a cross-sectional view of an exemplary embodiment of a pocketed spring seating unit 104 according to the present disclosure. Similar to conventional spring seating units, the pocketed spring seating unit 104 is configured to lay beneath, and provide support to cushions of a couch or sofa. Unlike conventional spring seating units, however, the pocketed spring seating unit 104 provides both a superior seating experience and durability.

The pocketed spring seating unit 104 generally comprises a spring array 108 enclosed within insulating materials and may be finished with an exterior cloth material or upholstery 112. The spring array 108 comprises a multiplicity of pocketed springs 116 placed side by side in a spring layer arrangement. Each of the pocketed springs 116 comprises a coil spring 120 covered with a flexible wrap 124, such as by way of example, a fabric or textile material. The coil springs 120 preferably are comprised of a metal such as spring steel, and have a “spring travel” depth of approximately 70% of the spring height.

Unlike conventional spring seating units that comprise connected springs attached by twine or steel, each of the pocketed springs 116 operates independently of the other pocketed springs within the spring array 108. As such, when a person sits on a sofa that includes the pocketed spring seating unit 104, the pocketed springs 116 operate similarly to a multiplicity of independent automobile shock absorbers, compressing to various degrees so as to contour the person's body and comfortably support the weight of the person. Further, as the person sits onto the sofa, the spring travel depth of the coil springs 120 provides a gentle increase in spring force until the weight of the person is borne by the spring array 108. It should be understood that the spring travel depth of the coil springs 120 coupled with the independent operation of the pocketed springs 116 provides a seating experience that is quiet, relatively deep, and conforms extremely well to the person's body, thereby conveying a relatively superior degree of comfort to the person.

In the illustrated embodiment of FIG. 4, the spring array 108 is enclosed within an envelope comprising insulating materials. As such, the envelope comprises a bottom insulating pad 128, a top insulating layer 132, and a side insulating layer 136. In some embodiments, the top and side insulating layers 132, 136 may be comprised of a combination of polyurethane foam and polyester padding. The bottom insulating pad 128 is positioned directly beneath the spring array 108, and the top insulating layer 132 is disposed directly above the pocketed springs 116. The side insulating layer 136 borders the perimeter of the spring array 108 and is disposed between the bottom insulating pad 128 and the top insulating layer 132 as shown in FIG. 4.

In some embodiments, the side insulating layer 136 may comprise a single piece of insulating material disposed around the perimeter of the spring array 108. Single pieces of insulating material are particularly advantageous for use in sofas or couches possessing rounded perimeter corners. In some embodiments, the side insulating layer 136 may comprise two or more pieces of insulating material that are positioned end to end so as to border the perimeter of the spring array 108. As will be appreciated, multiple pieces of insulating material may be advantageously utilized in sofas comprising square or rectangular perimeter shapes, or otherwise possessing angled perimeter corners.

As shown in FIG. 4, the bottom insulating pad 128 is fastened to a rigid platform 140. The rigid platform 140 may comprise a piece of plywood having a length and a width that suitably match the seating area of the sofa for which the pocketed spring seating unit 104 is intended to be used. The spring array 108 may be attached to the bottom insulating pad 128 and the rigid platform 140 by way of glue and suitable fasteners. The assembled pocketed spring seating unit 104 may be laid into an upholstery frame of the sofa and the rigid platform 140 may be attached thereto by way of a multiplicity of fasteners. As will be appreciated, the rigid platform 140 provides support to the spring array 108 and ensures that the pocketed springs 116 compress optimally under the weight of the person sitting thereon without creating undue stress, or horizontal forces, on the upholstery frame.

Moreover, the rigid platform 140 generally reduces the degree of structural reinforcement that needs to be incorporated into the upholstery frame. As will be appreciated, since the pocketed springs 116 operate independently of one another, substantially the entire force due to compression of the pocketed springs 116 is vertical and borne by the rigid platform 140. In absence of substantial horizontal forces, the upholstery frame need only be constructed to withstand relatively smaller, vertical forces due the weight of seated individuals.

Once the pocketed spring seating unit 104 is attached to the rigid platform, decorative seat cushions may then be placed atop the pocketed spring seating unit 104. In some embodiments, loose seat cushions may be positioned on top of the pocketed spring seating unit 104. It is contemplated that a flexible deck cover may be disposed on top of the pocketed spring seating unit 104 and attached to the upholstery frame so as to provide a finished appearance when the loose seat cushions are removed. In some embodiments, however, the seat cushions may of the attached variety, wherein the seat cushions are sewn directly onto the top of the pocketed spring seating unit 104.

While the invention has been described in terms of particular variations and illustrative figures, those of ordinary skill in the art will recognize that the invention is not limited to the variations or figures described. In addition, where methods and steps described above indicate certain events occurring in certain order, those of ordinary skill in the art will recognize that the ordering of certain steps may be modified and that such modifications are in accordance with the variations of the invention. Additionally, certain of the steps may be performed concurrently in a parallel process when possible, as well as performed sequentially as described above. To the extent there are variations of the invention, which are within the spirit of the disclosure or equivalent to the inventions found in the claims, it is the intent that this patent will cover those variations as well. Therefore, the present disclosure is to be understood as not limited by the specific embodiments described herein, but only by scope of the appended claims. 

What is claimed is:
 1. A pocketed spring seating unit for a couch or sofa, comprising: a spring array comprised of a multiplicity of pocketed springs disposed in a spring layer arrangement; an envelope comprised of insulating materials and surrounding the spring array; a rigid platform disposed below the envelope, the spring array and the envelope being attached to the rigid platform; and an exterior cloth material overlaying at least a portion of the envelope and the rigid platform.
 2. The seating unit of claim 1, wherein each of the multiplicity of pocketed springs comprises a coil spring covered with a flexible wrap.
 3. The seating unit of claim 2, wherein the coil spring is comprised of metal and configured to be compressed to a spring travel depth of at least 70% of the height of the coil spring when uncompressed.
 4. The seating unit of claim 1, wherein each of the multiplicity of pocketed springs is configured to operate independently.
 5. The seating unit of claim 1, wherein the envelope is comprised of at least a bottom insulating pad.
 6. The seating unit of claim 1, wherein the envelope is comprised of at least a bottom insulating pad, a top insulating layer, and a side insulating layer.
 7. The seating unit of claim 6, wherein at least the bottom insulating pad and the top insulating layer are comprised of a combination of polyurethane and polyester padding.
 8. The seating unit of claim 6, wherein the side insulating layer extends along the perimeter of the spring array and is disposed between the bottom insulating pad and the top insulating layer.
 9. The seating unit of claim 6, wherein the side insulating layer is comprised of one or more pieces of insulating material disposed around the perimeter of the spring array.
 10. The seating unit of claim 1, wherein the rigid platform has a length and a width that suitably match a seating area of the couch or sofa.
 11. The seating unit of claim 10, wherein the rigid platform is comprised of plywood, or a similar material.
 12. The seating unit of claim 1, wherein the rigid platform is configured such that the pocketed spring seating unit may be laid into an upholstery frame of the couch or sofa.
 13. The seating unit of claim 1, wherein the rigid platform is configured to support the spring array such that at least a portion of the multiplicity of pocketed springs compress optimally under the weight of a seated person without placing undue stress on an upholstery frame of the couch or sofa.
 14. The seating unit of claim 13, wherein the multiplicity of pocketed springs are configured to exhibit substantially vertical forces borne by the rigid platform, such that an absence of a substantial horizontal force is exerted on the upholstery frame.
 15. The seating unit of claim 1, wherein the pocketed spring seating unit is configured to be lifted vertically from an upholstery frame of the couch or sofa during servicing of the upholstery frame.
 16. A method for a pocketed spring seating unit to be incorporated into a couch or sofa, comprising: arranging a multiplicity of pocketed springs into a spring array; enclosing the spring array within an envelope of insulating materials; attaching the envelope and the spring array to a rigid platform; and overlaying an exterior cloth material onto one or more exterior surfaces of the envelope and the rigid platform.
 17. The method of claim 16, wherein arranging further comprises orienting the multiplicity of pocketed springs side by side so as to form a spring layer.
 18. The method of claim 16, wherein enclosing further comprises forming the insulating materials of a combination of polyurethane and polyester padding.
 19. The method of claim 16, wherein attaching comprises fastening the envelope and the spring array to the rigid platform by way of glue and suitable fasteners.
 20. The method of claim 16, wherein attaching further comprises configuring the rigid platform with a length and a width that suitably match a seating area of the couch or sofa. 